Knit article



May 29, 1962 o. w. HOLDER KNIT ARTICLE Filed March 8, 1961 United htatesPatent 3,036,450 KNIT ARTICLE Otis W. Holder, Mount Airy, N.C., assignorto Patent- Hose Corporation, Burlington, N.C., a corporation of NorthCarolina Filed Mar. 8, 1961, Ser. No. 94,336 16 Claims. (Cl. S5- 171)This invention relates generally to knit articles of the type whichcomprise an elongated tubular body and tapering portions extendingoutwardly therefrom. More particularly, the present invention relates toa knit `.article of the above type and a method of forming the samewherein opposite ends are provided with tie strings which are connectedto the tapered portions and extend out- Wardly therefrom. The knitarticle of the present invention is particularly adapted for use as ahead warmer and, when used as such, the elongated body is positionedacross the top of the head, covers the ears and the tie strings holdopposite ends together beneath the chin of the wearer. However, it is tobe understood that the knit article of the present invention may be usedfor other purposes.

Heretofore, the only known types of knitted head warmers manufacturedhave been formed by knitting an elongated flat strip of single thicknessmaterial and then cutting the ends at inclined angles to form taperedends to which tie strings are attached after the tapered edges arehemmed. In another type, an elongated tube is knit and flattened andthen opposite ends are cut at angles to form tapered end sections. Thesetapered end sections are then sewed together and tie strings areattached thereto. In both of these types, a considerable amount ofcutting and sewing is involved and this involves was-te and requiresexpensive equipment as well as skilled operators to manufactureconsistently first quality articles.

Accordingly, it is a primary object of the present invention to providea knit article having a tubular body and tapered end portions and amethod o-f knitting the same wherein the article is shaped during theknitting thereof and then requires a few relatively simple steps tofinish.

It is another object of the present invention to provide a knit articleof the type described which may be automatically knit on existingknitting machines of the type which are normally employed to producehosiery.

It is a further object of the present invention to provide a knitarticle of the type described which may be economically formed of asingle unitary, integrally knit blank which is strong in construction,requires a minimum of stitched seams and in which the type of stitchloops being formed can be easily v-aried in various portions of thearticle to produce different types of knit fabric in the desiredportions of the article,

Some of the objects of the invention having been stated, other objectswill appear as the description proceeds, when taken in connect-ion withthe accompanying drawings, in which- FIGURE l is a perspective view ofone side and end portion of the knit article when the same is used as ahead warmer and showing the same secured in position on the head of awearer;

FIGURE 2 is an isometric View of one side of the knit article blank instretched out condition and illustrating its appearance after it isremoved from the knitting machine and showing the central portion of thetubular body expanded to substantially a circular condition;

FIGURE 3 is a view similar to FIGURE 2, except showing the other side ofthe knit article blank, with the central portion of the tubular bodybroken away;

FIGURE 4 is a view similar to FIGURE 2, except ice showing the knitarticle in attened and finished condition;

FIGURE 5 is a fragmentary enlarged longitudinal vertical sectional viewthrough one end portion of the head warmer, being taken substantiallyalong the line 5-5 in FIGURE 4.

Although the knit article can be used for other purposes, it will bedescribed as a head warmer. When the head warmer is finished, as shownin FIGURE 4, it comprises a flattened elongated tubular body portion 10having tapered end portions, broadly indicated at 11 and 12, connectedto opposite ends of the body 10 and extending outwardly therefrom. Thetapered ends 11 and 12 include respective pairs of fashioned gussets 13,14 and- 15, 16 (FIGURES 3 and 4) and the corresponding pairs of gussetsare joined together along suture lines formed during the knittingthereof. The outer ends of the tapered ends 11 and 12 have one end ofsuitable tie strings 21 and 22 connected thereto. The tie strings 21 and22 are relatively narrow and extend outwardly away from the tap-eredends 11 and 12 (FIGURE 4).

The head warmer may be knit on a circular knitting machine of the typenormally employed to knit hosiery or it may also be knit on a V-bed atknitting machine capable of knitting tubular knit goods. It i-spreferred that the head warmer be knit on a circular machine and themethod of forming the same will be described in connection with thistype machine. In the present instance, a circular knitting machinehaving 60 needles in the cylinder is utilized, however, it is to beunderstood that a machine having a greater or fewer number of needlesmay be employed.

Knitting of the head warmer is begun by feeding yarn to the needles toform the usual make-up and in the present instance, yarn is fed toalternate needles and then to all of the needles to knit a first tubularportion 25 (FIGURE 2) which is formed of a plurality of successivecomplete courses, Any desired number of courses may be knit in thisfirst tubular portion 25 and in the present instance, 12 lcourses areknit. Since these courses will be later cut away and will not form aportion of the head warmer, they may be formed of a relatively cheapyarn before switching to the yarn from which the head warmer is formed.As the portion 25 is completed, a loose course or looper line 26 isformed of abnormally long stitches to aid in placing the stitch loops onthe points of a looper to finish the head Warmer, in a manner to belater described.

After completion of the tubular portion 25, half of the needles at oneside of the needle cylinder are moved to inactive position and retaintheir stitch loops thereon. Then, the knitting machine switches intoreciprocatory knitting to form partial courses with each knitting strokeof the cylinder on the remaining half of the needles in the cylinder tostart the knitting of the lgusset 13. As the successive partial coursesof the gusset 13 are knit, the number of needles knitting the succeedingpartial cou-rses is gradually reduced to gradually reduce the length ofthe partial courses in a well-known narrowing operation. During theknitting of the gusset panel 13, approximately 20 partial courses areknit with one needle being moved to inactive position by the narrowingpicks of the machine with each knitting stroke of the cylinder so thatapproximately ten needles remain in action when the gusset panel 13 iscompleted.

Reciprocatory knitting continues after completion of the gusset 13 withthe narrowing and widenin'g picks in action so that with each knittingstroke, successive partial courses which are l() needles wide are knitto fonn the relatively narrow tie string 21 (FIGURE 2). It is to beunderstood that the needles which were moved to inactive position duringthe knitting of the gusset 13 retain their stitch loops thereon duringthe' knitting of the tie string 21.

After a suicient number of partial courses have been knit to form thedesired length of tie string 21, the narrowing picks are moved toinactive position and the widening pick operates to bring additionalneedles into knitting position during succeeding knitting strokes. Asadditional needles are brought into action, the length of succeedingcourses of the gusset 14 is gradually increased in a well-knownwideningoperation. As the inactive needles are brought back into action, inknitting the gusset 14, the endmost stitch loops of the widened partialcourses are joined to the endmost stitch loops of the narrowed partialcourses of the gusset 13 to connect the gussets 13 and 14 together alongsutures indicated at S in FIGURE 5.

Upon completion of the last partial course of the gusset 14, all of theneedles are again activated and the machine switches into rotaryknitting to form the complete courses of the tubular body 10. The bodymay be formed of any desired stitch construction or it may be formed ofplain knitting, if desired. YIt is preferred that the body 10 beforrnedrof some type of stitch construction which hasan ornamentalappearance and which contrasts with the plain stitch fabric of thegussets 13 and 14. In the present instance, tuck stitches are formed inspaced apart wales to provide a plurality of raised rectangular puifs inthe body 10.

Upon completion of the proper number of complete courses to Vproduce thedesired lengths of body 10, half of the needles are again switched toinactive position, the machine switches into reciprocatory knitting andpartial courses are formed with each knitting stroke of the cylinder toform the gusset 15 (FIGURE 3). During the knitting of the gusset 15, thenarrowing picks are in operation to gradually reduce the number ofneedles knitting in succeeding partial courses and reduce the length ofthe partial courses in a narrowing operation. The inactivated needleshold the endmost stitch loops thereon until they are again activated.After substantially narrowed partial courses have been formed, reducingthe number of needles knitting by one needle in each partial course, themachine continues to reciprocate with the narrowing and widening picksin action tol thereby knit partial courses which are the same length onthe 10 remaining needles to form the tie string 22 (FIGURE 3).

After the desired number of partial courses have been knit to form thedesired length in the tie string 22, the narrowing picks are moved toinactive position and a Widening pick operates to begin increasing vthelength of the partial courses and knit the widened gusset 16 (FIG- URE2). As the partial courses are gradually increased in length, theinactive needles are gradually brought back into action and the stitchloops which theyrhave been holding are connected to the endmost stitchloops of the partial courses of the gusset panel 16 to join the edges ofthe gussets 15 and 16 together. When approximately 20 widened partialcourses have been knit, all of the needles are again activated and themachine switches into rotary knitting tov form stitches on all of theneedles and knit a tubular portion 30 (FIGURE 2). When knitting of thetubular portion 30 is begun, it is preferred that a loose course orlooper line 31 be formed of abnormally long stitches to yaid in placingthe tubular portion 30 upon the points of a looper to finish the headwarmer, in the manner to be presently described. After approximately 12courses have been formed in the tubular portion 30, the yarn feed fingeris moved to inactive position and the knit head warmer blank is shedfrom the needles of the knitting machine.

The head warmer blank is then nished by joining the last partial coursesofthe gussets 13 and 16 to portions of the terminal courses of the body10 by rows of stitching thread, indicated at 32 and 33 (FIGURE 4) whichare formed along the loose course lines 26 and 31. It is preferred thata conventional hosiery looper be employed to form the rows of stitchingthreads 32 and 33 because the looper is provided with a trimmer whichwill automatically cut away the tubular portions 25 and 3i) after thestitch loops of the loose courses 26 and 31 are impaled on the looperpoints. The tubular portions 25 and 30 serve to aid the operator inplacing the loose course lines 26' and 31 on the points of the looperand these tubular portions may also be referred to as loopers rounds.However, it is to be understood that the rows of stitching 32 and 33 atopposite ends of the head warmer blank may be formed by other types ofseaming or sewing machines, if desired.

The ends of the looped tie strings 21 and 22 are then cut adjacent thegussets 13 and 16 and along the respective dotted lines 34 and 35(FIGURE 2). This leaves a short tail or free end on each of the gussets13 and 16 which are tucked in between the corresponding gussets 13, 14and 15, 16 and sewed by rows of stitching threads indicated at 36 and 37in FIGURE 4. The rows of stitching threads 36 and 37 also join the outerends of corresponding pairs of gussets 13, 14 and 15, 16 together. Thefree ends of the tie strings 21 and 22 are then sewed with an overedgeseam to prevent raveling and then the head warmer is finished in aconventional manner.

Of course, if desired, the tie strings 21 and 22 may remain in loopedcondition and may be tied beneath the chin without severing the same.Also, the tie strings 21 and 22 do not have to be knit integral with thegussets of the tapered ends 11 and 12 but may be formed separately andattached to the tapered ends 11 and 12 later. If the tie strings 21, 22are attached after the head warmer is knit, they may be made of materialother than knit material, such as ribbon or the like.

When the tie strings 21, 22 and head warmer are formed separately, theouter ends of the corresponding pairs of gussets 13, 14 and 15, 16 willbe joined together during the knitting of the blank. Thus, the lastpartial course of the gusset 13 will be joined to the rst partial courseof the gusset 14 and the last partial course of the gusset 15 will bejoined to the iirst partial course ofthe gusset 16.

The head warmer blank of the present invention is completely fashionedon the knitting machine and requires very little manual sewing to finishthe same. Of course, the length of the head warmer may be varied byreducing or increasing the number of circular courses formed during theknitting of the tubular body portion 10 and the width of the head warmermay also be varied to some extent by varying the length of stitchesdrawn and greater variations in width can be obtained by using knittingmachines having larger or smaller needle cylinders.

In the drawings and specification there has been set forth a preferredembodiment of the invention and, although specic terms are employed,they are used in a generic and descriptive sense only and not forpurposes of limitation, the scope of the invention being defined in theclaims.

I claim:

1. A knit article comprising a tubular elongated Ibody portioncomprising a plurality of complete courses, and a pair of fashionedintegrally knit gussets having inner ends connected to opposite ends ofsaid body portion and outer terminal ends, each gusset comprising aplurality of partial courses connected to corresponding partial coursesof the corresponding gusset of said pairs.

2. A knit article comprising a tubular elongated body portion, a pair offashioned integrally knit gussets on each end of said body portion, saidpairs of gussets having inner ends connected to corresponding oppositeends of said body portion and outer terminal ends extending away fromsaid body portion, each of said pairs of fashioned gussets taperinginwardly from their inner ends to their terminal ends, and a relativelynarrow tie string attached at one end to the terminal ends of each ofsaid pairs of fashioned gussets.

3. In a knit article according to claim 2 wherein the knit materialforming said body portion is of a different construction than the knitmaterial of said pairs of gussets to provide a contrasting appearancebetween said body portion and said pairs of gussets.

4. A knit article comprising a tubular elongated body portion comprisinga plurality of complete courses, a pair of fashioned integrally knitgussets on each end of said body portion, said pairs of gussets havinginner ends connected to corresponding opposite ends of said body portionand outer terminal ends extending away from said body portion, each ofsaid fashioned gussets comprising a plurality of partial courses, thelength of the partial courses progressively decreasing from the innerends to the terminal ends of the gussets, and the ends of the partialcourses of one of each of said pairs of gussets being connected to theends of corresponding partial courses of the other gusset of said pairsof gussets.

5. A knit article comprising a tubular elongated body portion comprisinga plurality of complete courses, a pair of fashioned integrally knitgussets on each end of said body portion, said pairs of gussets havinginner ends connected to corresponding opposite ends of said body portionand outer terminal ends extending away from said body portion, each ofsaid fashioned gussets comprising a plurality of partial coursesconnected to corresponding partial courses of the corresponding gussetof said pairs, the length of the partial courses progressivelydecreasing from the inner ends to the terminal ends of the gussets, anda relatively narrow tie string attached at one end to the terminal endsof each of said pairs of fashioned gussets.

6. A knit article comprising a tubular elongated body portion, a pair offashioned integrally knit gussets on each end of said body portion, saidpairs of gussets having inner ends connected to corresponding oppositeends of said body portion and outer terminal ends extending away fromsaid body portion, the inner end of one gusset of each of said pairsbeing integrally knit with certain portions of corresponding ends ofsaid body portion, a stitching thread connecting the inner end of theother Agusset of each of said pairs to other portions of correspondingends of said body portion, each of said pairs of fashioned gussetstapering inwardly from their inner ends to their terminal ends, and arelatively narrow tie string attached at one end to the terminal ends ofeach of said pairs of fashioned gussets.

7. A knit article comprising a tubular elongated body portion, a pair offashioned integrally knit gussets on each end of said body portion, saidpairs of gussets having inner ends connected to corresponding oppositeends of said body portion and outer terminal ends extending away fromsaid body portion, each of said pairs of fashioned gussets taperinginwardly from their inner ends to their terminal ends, and a relativelynarrow knit tie string integrally knit with the terminal ends of atleast one of the gussets of each of said pairs of fashioned gussets.

8. A method of forming a knit article having an elongated tubular bodyinterknit with a pair of fashioned gussets extending outwardly from eachend of the tubular body which comprises the steps of knitting aplurality of partial courses while progressively reducing the length ofthe partial courses to form a first narrowed gusset, knitting aplurality of partial courses while progressively increasing the lengthof the partial courses to form a first widened gusset connected to thefirst narrowed gusset, knitting a plurality of complete courses to forma tubular body connected to the first widened gusset, knitting aplurality of partial courses while progressively reducing the length ofthe partial courses to form a second narrowed gusset connected to saidtubular body, knitting a plurality of partial courses whileprogressively increasing the length of the partial courses to form asecond widened gusset connected to the second narrowed gusset,connecting the first narrowed gusset to the tubular body, and connectingthe second widened gusset to the tubular body.

9. A method of forming a knit article having an elongated tubular bodyinterknit with a pair of fashioned knit gussets connected to andextending outwardly from each end of the tubular body which comprisesthe steps of knitting 4a plurality of partial courses while graduallyreducing the length of the partial courses to form a first fashionedgusset, knitting a plurality of partial courses while graduallyincreasing the length o f the partial courses to form a second fashionedgusset connected to the first gusset, knitting a plurality of completecourses to form a tubular body connected to the second gusset, knittinga plurality of partial courses while gradually reducing the length ofthe partial courses to form a third fashioned gusset connected to saidtubular body, knitting a plurality of partial courses while gradaullyincreasing the length of the partial courses to form a fourth fashionedgusset connected to the third gusset, connecting the initial partialcourse of the first gusset to a portion of the initial complete courseof the tubular body, and connecting the last partial course of thefourth gusset to a portion of the last complete course of the tubularbody.

10. A method of forming a knit article, such as a head warmer, having anelongated tubular body interknit With a pair of fashioned gussetsextending outwardly from each end of the tubular body, and tie stringsinterknit with the `gussets and extending outwardly therefrom whichcomprises the steps of knitting a plurality of partial courses whilegradually reducing the length of the partial courses to form a firstfashioned gusset, knitting a plurality of partial courses of the samelength to form a first tie string connected to the first gusset,knitting a plurality of partial courses while gradually increasing thelength of the partial courses to form a second fashioned gussetconnected to the first gusset and to the tie string, knitting aplurality of complete courses to form a tubular body connected to thesecond gusset, knitting a plurality of partial courses while graduallyreducing the length of the partial courses to form a third fashionedgusset connected to said tubular body, knitting a plurality of partialcourses of the same length to form a second tie string connected to thethird gusset, knitting a plurality of partial courses while graduallyincreasing the length of the partial courses to form a fourth fashionedgusset connected to the third gusset and to the tie string, connectingthe initial partial course of the first gusset to a portion of theinitial complete course of the tubular body, and connecting the lastpartial course of the fourth gusset to a portion of the last completecourse of the tubular body.

11. In a method according to claim l0 including the steps of cutting thefirst tie string adjacent its point of connection with the secondgusset, cutting the second tie string adjacent its point of connectionwith the fourth gusset, sewing together the first and second gussets lata point adjacent the first tie string, and sewing together the third andfourth gussets at a point adjacent the second tie string.

12. A method of forming a blank for a knit article having an elongatedtubular body and a pair of fashioned knit gussets connected to andextending outwardly from each end of the tubular body which comprisesthe steps of'knitting a plurality of partial courses while graduallyreducing the length of the partial courses to form a first fashionedgusset, knitting a plurality of partial courses while graduallyincreasing the length of the partial courses to form a second fashionedgusset while connecting the ends of the partial courses of the secondgusset to the ends of the partial courses of the first gusset, knittinga plurality of complete courses to form a tubular body With -a portionof the initial complete course thereof being connected to the terminalpartial course of the second gusset, knitting a plurality of partialcourses while gradually reducing the length of the partial courses toform a third fashioned gusset with the initial partial course of thethird gusset being connected to a portion of the terminal completecourse of the tubular body, and knitting a plurality of partial coursesWhile gradually increasing the length of the partial courses to form afourth fashioned gusset while connecting the ends of the partial coursesof the fourth gusset to the ends of the partial courses of the thirdgusset.

13. A method of forming a blank for a knit article having an elongatedtubular body, a pair of fashioned knit gussets connected to andextending outwardly from each end of the tubular body, and tie stringsconnected to and extending outwardly from the fashioned gussets whichcomprises the steps of knitting a plurality of partial courses Whilegradually reducing the length of the partial courses to form a firstfashioned gusset, continuing to knit a plurality of partial courses butof equal length to form a first tie string of uniform width, continuingto knit a plurality of partial courses while gradually increasing thelength of the par-tial courses to form a second fashioned gusset whileconnecting the ends of the partial courses thereof to corresponding endsof the partial courses of the first gusset, knitting a plurality ofcomplete courses to form a tubular body while interknitting the firstcourse thereof with the last partial course of the second gusset,knitting a plurality of partial courses while gradually reducing thelength of the partial courses to form a third fashioned gusset Whileinterknit-ting the first partial course thereof to a portion of the lastcomplete course of the tubular body, continuing to knit a plurality ofpartial courses but of equal length to form a second tie string ofuniform Width, and continuing to knit a plurality of partial courseswhile gradually increasing the length of the partial courses to form afourth fashioned gusset While connecting the ends of the partial coursesthereof to the corresponding ends of the partial courses of the thirdgusset. i

14. A method of forming a blank for a knit article having an elongatedtubular body, and a pair of fashioned knit gussets interknit with andextending outwardly from each end of the tubular body which comprisesthe steps of knitting a plurality of complete courses to form firstloopers rounds, knitting a plurality of partial courses while graduallyreducing the length of the partial courses to form a first fashionedgusset with the initial partial cou-rse of the first gussetrbeinginterknit with a portion of the last complete course of the firstloopers rounds, kntting a plurality of partial courses while graduallyincreasing the length of the partial courses to form a second fashionedgusset While connecting the ends of the partial courses of the secondgusset to the ends of the partial courses of the first gusset, knittinga plurality of complete courses to form a tubular body with a portion ofthe initial complete course thereof being interknit with the lastpartial course of the second gusset and with the other portion of theinitial complete course of the tubular body being interknit with aportion of the last complete course of `the loopers rounds, knitting aplurality of partial courses while gradually reducing the length of thepartial courses to form a third fashioned gussetwith the initial partialcourse of the third gusset being interknit with aV portion of the lastcomplete course of the tubular body,V

knitting a plurality of partial courses while gradually increasing thelength of the partial courses to form a fourth fashioned gusset whileconnecting the ends of the partial courses of the fourth gusset to theends of the partial courses of the third gusset, and knitting aplurality of complete courses to form second loopers rounds with aportion of the initial complete course thereof being interknit with thelast partial course of the fourth gusset and with the other portion ofthe initial complete course of the second loopers rounds being interknitwith a portion of the last complete course of the tubular body.

15. A method of forming a blank for a knit article having an elongatedtubular body, a pair of fashioned knit gussets connected to andextending outwardly from each end of the tubular body, and tie stringsconnected to and extending outwardly from the fashioned gussets whichcomprises the steps of knitting a plurality of cornplete courses to formfirst loopers rounds, knitting a plurality of partial courses whilegradually reducing the length of the partial courses to form a firstfashioned gusset, continuing to knit a plurality of partial courses butof equal length to form a first tie string of uniform width, continuingto knit a plurality of partial courses while gradually increasing thelength of the partial courses to form a second fashioned gusset whileconnecting the ends of the partial courses thereof to the correspondingends of the partial courses of the first gusset, knitting a plurality ofcomplete courses to form a tubular body while interknitting the firstcourse thereof with the last partial course of the second gusset and aportion of the last complete course of the first loopers rounds,knitting a plurality of partial courses while gradually reducing thelength of the partial courses to form a third fashioned gusset whileinterkniting the first partial course thereof to a portion of the lastcomplete course of the tubular body, continuing to knit a plurality ofpartial courses but of equal length to form a second tie string ofuniform width, continuing to knit a plurality of partial courses whilegradually increasing the length of the partial courses to form a fourthfashioned gusset While connecting the ends of the partial coursesthereof to the corresponding ends of the partial courses of the thirdgusset, and knitting a plurality of complete courses to( form secondloopers rounds while interknitting the first course thereof with thelast par-tial course of the fourth gusset and With a portion of the lastcomplete course of the tubular body.

16. AV method of forming a knit article having an elongated tubular bodyinterknit with a pair of fashioned gussets extending outwardly from eachend of the tubular body which comprises the steps of knitting a firstplurality of par-tial courses while progressively reducing the length ofat least the first knit partial courses While progressively increasingthe length of at least the last knit partial courses and while joiningtogether the ends of the progressively reduced and the progressivelyincreased partial courses, knitting a plurality of complete courses toform a tubular body, and then knitting a second plurality of partialcourses while progressively reducing the length of the partial coursesof at least the first knit partial courses while progressivelyincreasing the length of the last knit partial courses and while joiningtogether the ends of the progressively reduced partial courses andtheprogressively increased partial courses.

References Cited in the file of this patent UNITED STATES PATENTS1,072,735 Kellner et al. Sept. 9, 1913 1,157,341 Tallerday Oct. 19, 1915FOREIGN PATENTS 548,850 Belgium July 14, 1956

